Art of producing electrical conductors from cord wire



17 Sheets-Shet l K. H. ANDREN ART OF PRODUCING ELECTRICAL CONDUCTORS FROM CORD WIRE o 0.:0 o o 0 :0 9

Nov. 8, 1966 Filed April 26, 1962 ATTORN EYS.

INVENTOR KARL H. ANDREN .OOOOOOOOOOOOOOOOOOOOOOOOOUOOOO Nov. 8, 1966 K. H. ANDREN 3,283,398

ART OF PRODUCING ELECTRICAL CONDUCTORS FROM CORD WIRE Filed April 26. 1962 17 Sheets-Sheet 2 N INVENTOR.

KARL H.ANDREN BY ww w ATTOR N EYS.

Nov. 8, 1966 K. H. ANDREN 3,

ART OF PRODUCING ELECTRICAL CCNDUCTORS FROM CORD WIRE Filed April 26, 1962 1.7 Sheets-Sheet 5 Wm. H

INVENTOR.

KARL H. ANDREN ATTORNEYS.

1.7 Sheets-Sheet 4 INVENTOR. KARL H. ANDREN fiegmfiwwfi w ATTORNEYS.

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Nov. 8, 1966 ART OF rnonucme ELECTRICAL CONDUCTORS FROM coRD WIRE Filed April 26, 1962 K. H. ANDREN Nov. 8, 1966 ART OF PRODUCING ELECTRICAL CONDUCTORS FROM CORD WIRE Filed April 26. 1962 L7 Sheets-Sheet 5 WW Ad 80 'IIIIIIIIIII INVENTOR.

KARL H. ANDREN Www BY $5.2M

ATTORNEYS.

Nov. 8, 1966 K. H. ANDREN 3,283,398

ART OF PRODUCING ELECTRICAL CONDUCTORS FROM CORD WIRE Filed April 26, 1962 17 Sheets-Sheet e INVENTOR.

KARL H. ANDREN I LJJ ma ATTO NEYS.

ART OF PRODUCING ELECTRICAL CONDUCTORS mom CORD WIRE Filed April 26, 1962 K. H. ANDREN Nov. 8, 1966 L7 Sheets-Sheet 7 llm llll INVEN TOR.

KARL. H. ANDREN W war/$ 12M ATTORNEYS Nov. 8, 1966 K. H. ANDREN 3,

ART OF PRODUCING ELECTRICAL CONDUCTORS FROM CORD WIRE Filed April 26, 1962 1.7 SheetsSheet 8 INVENTOR. KARL H. ANDREN BY mzwwww ATTORNEYS.

K- H. ANDREN Nov. 8, 1966 ART OF PRODUCING ELECTRICAL CONDUCTORS FROM CORD WIRE Filed April 26, 1962 1,7 Sheets-Sheet 9 LET/Q s a 12;

KARL H. ANDREN K. H. ANDREN Nov. 8, 1966 I ART OF PRODUCING ELECTRICAL CONDUCTORS FROM CORD WIRE Filed April 26, 1962 L7 Sheets-Sheet l1 INVENTOR. KARL H. ANDREN ATTORNEYS.

Nov. 8, 1966 K. H. ANDREN 3,283,398

ART OFPRODUCING ELECTRICAL CONDUCTORS FROM CORD WIRE Filed April 26, 1962 L7 Sheets-Sheet 12 .E i .i8.

INVENTOR. KARL H. ANDREN ATTORNEYS.

ART OF PRODUCING ELECTRICAL CONDUCTORS FROM CORD WIRE Filed April 26, 1962 K. H AN DREN Nov. 8, 1966 L7 Sheets-Sheet 15 INVENTOR. K ARL H ANDREN BY WWW/5 2M ATTORNEYS.

K. H. ANDREN- Nov. 8, 196 6 ART OF PRODUCING ELECTRICAL CONDUCTORS FROM CORD WIRE Filed April 26, 1962 17 Sheets-Sheet l4 vIIl'IIIIlIIIIIfilIlII/II/I/A' INVENTOR. KARL H. ANDREN ATTOR NEYS.

Nov. 8, 1966 K. H. ANDREN 3,283,393

ART OF PRODUCING ELECTRICAL CONDUCTORS FROM CORD WIRE Filed April 26. 1962 17 Sheets-Sheet 15 3407 all/x Y P 1* HQ INVENTOR. KARI. H. ANDREN ATTOR NEYS.

K. H. ANDREN Nov. 8, 1966 ART OF PRODUCING ELECTRICAL CONDUCTORS FROM CORD WIRE Filed April 26. 1962 1.7 Sheets-Sheet l6 INVENTOR. KARLHHANDREN ATTORNEYS.

ART OF PRODUCING ELECTRICAL CONDUCTORS FROM com) WIRE Filed April 26. 1962 K. H. ANDREN Nov. 8, 1966 1.7 Sheets-Sheet 1? ATTORNEYS.

United States Patent 3,283 398 ART OF PRODUCING ELECTRICAL CONDUCTORS FROM CORD WIRE Karl H. Andren, West Allis, Wis., assignor to Artos Engineering Company, Milwaukee, Wis., a corporation of Wisconsin Filed Apr. 26, 1962, Ser. No. 190,402 9 Claims. (Cl. 29155.55)

This invention relates generally to improvements in the art of producing electrical conductors from cord wire stock, and it relates more specifically to an improved method of and apparatus for accurately manufacturing conductors of various types and lengths from continuous cord wire in rapid succession.

' The primary object of the present invention is to provide an improved method of rapidly and accurately producing successive electrical conductor cords of diverse kinds from a continuous supply wire, and to also provide eflicient mechanism for automatically commercially exploiting the improved method.

A number of different kinds of machines for producing various types of electrical conductors from cord wire have heretofore been proposed and used quite extensively, but due to the tremendous demand for such conductors and to the fact that the conductor requirements are becoming more intricate and that successive conductors of each type must be produced identically and with utmost precision, these prior mechanisms have failed to meet all of the commercial demands and requirements. In these so-called electric cords, two or more insulation-coated wires have plastic coatings which are molded together laterally, and in order to properly apply terminals of various types, the coating at the opposite ends of each cord wire must be slitted to separate the individual strands, and usually the insulation must also be removed at these wire ends before the terminals can be attached thereto. The terminals used in these machines are fed into the attaching mechanisms in the form of strips from which the individual terminals must be severed as required.

Most of the prior conductor cord producing methods and machines were restricted either to applying a terminal only to one end of each wire or cord, or to the opposite ends of a single wire only, and none of the previous mechanisms were adapted to apply terminals to multiple or single wire cords by feeding the terminal strips either laterally or longitudinally of the wires. With the prior machines wherein a terminal was attached to each end of a single Wire, these terminals were also applied successively in the same operating zone, thereby materially limiting the speed of operation and the capacity of the machines. Then, too, in all prior machines, the terminal attaching zones were very restricted as to sizes and types of terminals that could be attached therein, and none were capable of applying several different kinds of terminals to each of the opposite ends of a cord. With the restricted attaching zones of the previous mechanisms, it was extremely difficult to feed long ground pin terminals into proper position for attachment with required accuracy and at high speed.

The present invention therefore contemplates the provision of a method and equipment whereby higher speed of production is made possible with far greater accuracy and range of control, and which is also effectively exploitable for producing conductor cords having predetermined lengths adjustable during normal operation and which could not be accomplished with any prior methods.

The invention also provides an improved method whereby multiple wire cords formed from ribbon stock in which the wires are disposed laterally in a common plane have their opposite severed ends presented to diverse tools which perform their operations perpendicular to the rib- 3,283,3Q3 Patented Nov. 8, 1966 bon plane, and wherein the terminals may be fed either laterally or longitudinally toward the wire ends.

These and other more specific objects and advantages of the invention will be apparent from the following detailed description from which it will be apparent that the improved method comprises in general the steps of (l) severing successive predetermined lengths from a continuous' cord wire ribbon fed longitudinally through one zone, (2) folding each severed length into a loop to place its opposite ends flatwise in juxtaposition and gripping the folded length inwardly of its extreme juxtaposed ends, (3) moving the folded wire to position its juxtaposed ends within a second zone remote from the severing zone, (4) simultaneously conditioning both ends of each wire within the second zone and thereafter also applying terminals from terminal strip fed either laterally or longitudinally of the wires toward any or all of the pre-conditioned wire ends, and (5) successively removing the finished conductors from the second zone while severing new wire lengths in the first zone.

A clear conception of the several steps constituting the improved method, and of the construction and operation of one type of machine for effecting automatic performance of the method, may be had by referring to the drawings accompanying and forming a part of this specification wherein like reference characters designate the same or similar parts in the various views.

FIG. 1a is a side elevation of the front half of a commercial machine for exploiting the present improved method of producing electrical conductors from cord ribbon;

FIG. 1b is a side elevation of the rear half of the same machine;

FIG. 2 is an end view taken from the left of the same machine as viewed in FIGS. 1a and 1b;

FIG. 3a is a top view of the front end of the machine, a partial section having been taken along the line BE of FIG. 1;

FIG. 3b is a top view of the rear end portion of the machine with a small portion thereof broken away;

FIG. 4 is an enlarged horizontal section through a portion of the same machine, viewed from the left and taken approximately along the line AA of FIG. la;

FIG. 5 is a similarly enlarged horizontal section through the machine, also taken along the line AA of FIG. 1a showing the mechanism in one position;

FIG. 6 is a similar section taken along the line AA but showing the mechanism in another operating position;

FIG. 7 is also a similar section taken along the line AA, but also showing the mechanism in still another operating position;

FIG. 8 is a vertical section through the machine taken along the line BB of FIG. 1a but with some parts omitted for the sake of clarity;

FIG. 9 is a more complete vertical section taken along the line C--C of FIG. 3a, but showing the mechanism at a different time from that of FIG. 8;

FIG. 10 is a longitudinal vertical section through the rear of the same machine, taken along the line DD of FIG. 3a;

FIG. 11 is an enlarged fragment of a portion of the mechanism shown in section in FIG. 10;

FIG. 12 is an enlarged section taken horizontally through the upper 'oonveyor driving gear box of FIG. 2, taken along the line K-K of FIG. 13, and showing its internal mechanism;

FIG. 13 is a vertical section through the conveyor drive box of FIG. 12, taken along the line II of FIG. 2;

FIG. 14 is an enlarged top view of the lower variable speed drive box with top cover removed and with fragmentary sections as shown in FIG. 2, taken along the line HH thereof;

the line MM of FIG. 1a, showing the cord clamping mechanism;

FIG. 17 is an enlarged part sectional side elevation of one of the cord length carriers;

i FIG. 18 is an enlarged part sectional view of the cord end slitting and stripping unit of the machine taken approximately along the dividing line of FIGS. and 1b;

FIG. 19 is a similarly enlarged end view of the unit shown in FIG. 18;

1 FIG. 20 is a likewise enlarged vertical section through the unit of FIG. 18 taken along the line H--H of FIG. 18;

FIG. 21 is an enlarged end elevation of one of the terminal-attaching devices and the driving cam thereof, taken along the line GG of FIG. 3b;

FIG. 22 is an enlarged side view of the mechanism shown in FIG. 21;

FIG. 23 is .an end view of one type of finished conductor collecting mechanism of the machine;

FIG. 24 is an enlarged horizontal section through the mechanism of FIG. 23 taken along the line PP;

FIG. 25 is an enlarged vertical transverse section through the mechanism of FIG. 23 taken along the line R-R;

FIG. 26 is an enlarged transverse vertical section through the conductor pick-up mechanism taken along the line F-F of FIG. 23, showing the transfer elements in final delivering position;

FIG. 27 is a similar section showing the transfer elemcnts in position ready to receive a subsequent conductor;

FIG. 28 is another similar view showing the position of the elements while picking up another completed conductor;

FIG. 29 is a plan view of one type of finished conductor showing various types of terminals attached to a ribbon cord length;

FIGS. 30 to 37 show various types of terminal strips which may be fed into the machine to produce conductors of various kinds;

- FIG. 38 is a timing diagram for the machine when carrying on the improved method.

While the improved method of producing electrical conductors from cord stock has been described herein as being automatically exploitable with the aid of a particular type of mechanism illustrated herein, it is not intended to restrict the invention to the .use of such specific apparatus for carrying on the method steps; and it is also contemplated that specific descriptive terms employed herein 'be given the broadest possible interpretation consistent with the disclosure.

Referring to the drawings, the conductor production mechanism shown therein by way of illustration comprises in general, a cable or cord feeding device 10 adapted to withdraw continuous cord stock 9 from a supply reel 8; a conveyor loading device 11 for actuating a cord stock transfer mechanism 12 with its gripper 231 (FIGS. 3a, 8, and 11); a cord gatherer 17 for assisting in gathering cord stock 9 withdrawn from the reel 8 (FIG. a severer 13 for cutting successive predetermined lengths 15 of cord stock 9 from the continuous supply (FIGS. 1a, 3a); an intermittently movable endless chain conveyor 14 (FIGS. 1a, 3a, 15, and 17) having thereon a series of U-shaped carriers 20, a first carrier 19 and a second carrier 20, for gripping and carrying the opposite ends 16 of each severed cord length 15 in juxtaposition; a number of interconnected cooperating units 21 disposed at different positions along the path of advancement of the cord carriers by the conveyor 14 and being operable to successively slit, strip, stagger cut, and attach various types of terminals to both ends 16 of each cord length 15; and mechanism for finally removing the finished conduc- 4; tors at an unloading station 21 and for depositing them into a receiver 22 adapted to be unloaded during normal operation of the machine (FIGS. 1b and 3b).

The carriers 19, 20, 20 are secured to the endless chain of the conveyor 14 equidistant-apart and are adapted to engage fixed parallel guide bars 25, 25' secured to a sturdy channel beam 24 firmly attached with spacers 23.to a

main table frame 30 supported on legs 26, see FIGS. 1

to 3 and 16. The conveyor 14 is intermittently operable from an upper drive box 33 (FIGS. 2, 12, and 13) mounted on spacers 36 carried by the frame 30, and is adapted to 'be driven by a shaft 27 andi-ntenmeshing gears 28 which are indexed by a Geneva drive 31, this shaft being locked during the dwell period by a cam actuated locking element 29. The Geneva drive 31 is driven from a main indexing shaft 32' journalled in the drive box 33 and which shaft in turn is driven by reduction gears'34,35

and by a timing belt drive 40 through a main drive shaft 41 and another belt drive 42 from an electric motor 43 (FIGS. 2 and 3a). I

The drive shaft 41 is journalled in a lower drive box 50 also carried by the table 30, and provides a variable speed friction drive for the cord feeding device 10 (FIGS.

3a and 14), through bevel gears 51, a drive shaft 52, a driving friction disc 53 coacting through a friction roller 55 with a friction disc 54 mounted on a drive shaft 60, which shaft also carries a one-way clutch gear 61. The roller 55 is axially adjustable by means of a freely mounted positioning bar 56 movable by a screw 57 adapted to be rotated by a hand wheel 58 through a chain drive 58- and the axial static friction pressure required is exerted by set screw 62 pressing through the flat spring 63 on the thrust and radial bearing 64. The one-way clutch 61 is adapted to drive a pair of intermeshing gears 70, 71 (FIGS/2 and 14) which are drivingly connected through universal joints 73 and drive shafts 75 with a pair of pinch rollers journalled inlevers 81 fulcrurned on pivots 82 in a bracket 83 which is suspended from the channel bar 24 (FIGS. 4, 5, 6, 7, 9, and 10).

The pinch roller supporting levers 81 are movable toward and away from each other by connecting rods attached to geared levers 91 operable by a compression spring 92 attached to the channel bar 24 and which coacts with another connecting rod 93 attached to one of a the levers 91 and to a bell crank 94 swingable about a fulcrum 95 carried by a bracket 96 on the channel bar 24 (FIG. 10). The bell crank 94 is provided with a roller adapted to be engaged by a cam lug 101 on a cam 102 mounted upon the shaft 32 to momentarily separate the spring loaded pinch rollers 80 equidistant from the opposite sides of the ribbon cord 9 through the linkage just described, and an attendant may also adjust the feeding length of the cord stock 9 by manipulating the hand wheel 58 While the machine is operating Each of the U-shaped carriers. 19, 20, and 20' which are attached to the endless chain conveyor 14 comprises a leader clamp 103 adapted to engage the leading end of a cord length and a trailer clamp 104 adapted to engage the trailing end of the same looped cord length after same has been severed from the cord stock 9, and.

to firmly hold and carry these two ends in juxtaposition (FIGS. 1b, 16, and 17). interconnected by a frame 105 forming two separate parallel guideways which engage the guide bar 25, and are rigidly united by a central part to which a short guide block 111 adapted to engage the other. guide bar 25' is attached.

Each of the carrier clamps 103, 104 is provided with a fixed anvil 112 and a sliding jaw 113 which is normally retained in open position by a spring 114 and is confined in a guide slot 121 by a cover plate 122. The end of the slide jaw 113 nearest to the conveyor chain is provided with a notch within which a locking wedge 123 is slidably engaged and tends to move outwardly under the influence of a spring 124 coacting with a cross The two clamps 103, 104 are bar 125, but the wedge is prevented from moving until the end 116 of the jaw 113 is pressed down upon the yielding cord 15 whereupon the jaw 113 will be locked into that position by the wedge. The cord will thus remain clamped as compressed in the leading jaw 103 until the carrier 20 arrives at the unloading station 21' whereupon the locking wedge is rushed back and the jaw 113 is released by its spring 114, as will be later described.

Whenever the indexing and transporting conveyor 14 has indexed the advancing carrier 19 with a cable end 16' of a loop 15' which is carried across the pathway of conveyor 14 from the supply reel 8 through a drag block 285 and between the pinch rollers 80 by the gripper 231, said conveyor also advances the second carrier 20' to a dwelling period in a first loading position for loading its leading clamp 103. Said clamp with its open jaws 112, 113 has just received a median portion of the cord 9 as will be described later. The upper end 116 of this jaw 113 will then be depressed by the spring loaded plunger 130 to clamp and lock said cord 9 (FIG. 17), and said cord will be severed by the severer 13. Said spring loaded plunger 130 is mounted on a lever 131 secured to an operating shaft 132 journalled in a bracket 132' carried by the channel 24 (FIGS. 1a, 8, 9, and The other end of this shaft is secured to a. lever 133 connected by a drag link 134 to the upper end of a cam lever 135, the opposite end of which carries a roller adapted to engage a cam 136 and biased toward this cam by a spring 137. When the cord 9 has been severed, the end carried by the gripper 231 becomes the trailing end 16 of the new cord and this end 16 is turned around and inserted into the trailing clamp 104 to bring these cord ends into flat juxtaposition as will be described later. The end 116 of the clamping jaw 113 of the clamp 104 is operated in a similar manner by a spring pressed plunger 140, a lever 141, a shaft 142, a lever 143, and a drag link 144 through a cam lever 145 which is engageable with a cam 146 and is biased toward the latter by a spring 147 (FIGS. 3a, 10, and 16).

In order to insure that the cord 9 will be properly transferred from the cord stock transfer mechanism 12 and delivered to the leading clamp 103, a cable support 150 having a hook 151 for lifting the cord 9 carried by the gripper 231 slightly above the anvil 112 of the approaching clamp 103 is provided, and this hook also provides proper lateral or side location of said cord. This cable support 150 is adapted to swing in timed relation as indicated in dot-and-dash lines in FIG. 15, and is operable by a multiple linkage 152 mounted on the frame 30 which is actuated by an oscillatory shaft 153 cooperating through a spring biased pinion and rack 154 and with cam lever 156 with a cam 155 carried by the shaft 32 (FIGS. 2 and 3a).

The cable cutting device 13 is also supported on the frame 30 and comprises a lower knife 160 mounted on a bell crank pivoted on a shaft 161, an upper knife 162 mounted upon another bell crank attached to and swingable by a shaft 163, a spring 164 for urging the knives 160, 162 toward each other like a pair of shears, and a pair of links 165 connecting both knives with a slidable rod 166 (FIGS. 1a, 2, and 3a). The rod 166 is urged in one direction by a compression spring 167 to normally maintain the knives 160, 162 in open position, and this rod coacts through linkage 168 and a lever 169 fulcrumed on a shaft 171 with a cam 170 carried by the cam shaft 32.

The conveyor loading device (FIGS. 4 to 11) is confined within a housing 175 having inverted U-shaped cross section and which is firmly secured to the channel bar 24. Two reciprocable racks 176, 176' are disposed within this housing 175 but have their supporting bearings 177, 178 mounted externally of the housing, and these racks support a grooved bar 179 which is adapted to engage a roller 180. The racks 176 are reciprocable by pinions 181 secure-d to a drive shaft 182 journalled in the bearings 177, and the shaft 182 has a crank 183 attached thereto and which is operable by a link 184 connected to a cam actuated lever 185 fulcrumed on a shaft 186 and which is adapted to be actuated by a cam groove formed in one side of a rotary cam 187 (FIGS. 2 and 3a). The opposite side of the cam 187 is provided with another cam groove which coacts with a cam lever 192 also fulcrumed on the shaft 186 and which is connected by a link 193 with a rocker arm 194 secured to the upper end of an upright shaft 195 journalled in a bearing block 196 mounted upon the housing 175. This shaft 195 has another rocker arm 197 with a contact surface 198 and is connected by a link 199 to another similar rocker arm 197' on an upright shaft 195 with a contact surface 198, see FIGS. 4 to 7, the function of which will be later described.

The lower portion of the housing is provided with a guideway 205 and with gibs 206 (FIG. 10) adapted to cooperate with a reciprocable hollow frame shuttle 207 (FIGS. 8 and 9) which is operable by a link 208 connected to an end of a lever 209 (FIGS. 3a and 5 to 7). This lever 209 has its opposite end welded to one end of a pivot bar 210 and is also firmly connected thereto by a brace 211, and this assemblage is mounted on a pivot pin 212 which projects at both ends through a stand 213 mounted upon the frame 30. The other end of the bar 210 is connected by a link 214 to a rocker arm comprising plates 215 and a hub 216, and these plates carry rollers 217 adapted to coact with a master cam 218 and a conjugate cam 219 mounted on the cam and indexing shaft 32 (FIG. 2).

The opposite end of the shuttle 207 (FIGS. 4 to 8) is closed at the top and bottom and houses a shuttle arm 227, the medial portion of which passes through the hollow shuttle and is pivoted on a pin 229. The outer end of the shuttle arm 227 is bifurcated and carries a cord gripper 231 which is mounted for oscillation with an attached pinion 232 on a pin 233 carried by the member 230. The inner end of the shuttle arm 227 extends into the hollow shuttle 207 and carries a roller, the roller coacting with the grooved bar 179. The cord gripper 231 together with its pinion 232 is movable between stops 240, 241, on the shuttle arm 227' of the shuttle 207, and the pinion 232 is rotatable by means of a rack 242 slidable along a grooved backing plate 243, and the end of the rack 242 remote from the plate 243 is supported and guided by a bracket 244 mounted on the shuttle arm 227. A spring loaded plunger 245 is also mounted on the arm 227 between the pivot 229 and the roller 180 and coacts with an abutment 246 on the rack 242 to alternately force the gripper 231 against the stops 240, 241 while this rack is being reciprocated by a depending pin 247 on the end of rack 242 contacting with the surfaces 198, 198 during reciprocation of the shuttle 207 by the drag link 208 (FIGS. 5 and 8).

The cord stock gripper 231 comprises a body 252 having a gibbed guideway 253 coacting with a gripping slide 254 having a forked clamping foot 255 cooperating with a similarly forked plate 256 permanently attached to the body 252 (FIGS. 8, 9, and 11). The gripper is formed to straddle the path of advancement of the trailing clamps 104 of the carriers 20 secured to the conveyor 14, and the slide 254 projects upwardly within the guideway 253 and is adapted to be engaged to actuate the gripping foot 255 by means of a slide 257 slidably mounted in a plate 258 secured to the housing 175. The slide 257 engages the slide 254 so as to impart gripping pressure to the foot 255 against the cord stock 9, and the slide 257 is operable by a plunger 259 coacting with a strong spring 267 adjust-able by means of a screw 260. The plunger 259 is mounted in a bell crank 261 which is pivoted. in blocks 262 mounted on the housing 175 and is operable by a drag link 263 from a cam lever 264 cooperating with a cam lug 265, and this linkage is 

1. THE METHOD OF PRODUCING SUCCESSIVE LENGTHS OF ELECTRICAL CONDUCTORS FROM CONTINUOUS INSULATED WIRE STOCK, WHICH COMPRISES, ADVANCING THE WIRE LONGITUDINALLY PREDETERMINED DISTANCES BEYOND A SEVERING ZONE TO PROVIDE A SUCCESSIVE WIRE LENGTHS, REVERSING ONE END OF EACH SUCCESSIVE WIRE LENGTH TO LOOP THE SAME AND BRING THE OPPOSITE ENDS THEREOF INTO PREDETERMINED LATERALLY-SPACED JUXTA-POSITION WITH SAID ENDS POINTED IN A COMMON DIRECTION, FIRMLY GRIPPING EACH SUCCESSIVE LENGTH OF LOOPED WIRE INWARDLY OF EACH END THEREOF AT SAID PREDETERMINED POSITIONS TO MAINTAIN THE PROTRUDING ENDS IN LATERALLY-SPACED JUXTA-POSITION AND SUBSTANTIALLY PARALLEL RELATION WITH THE LOOP FREELY SUSPENDED, INTERMITTENTLY MOVING THE LENGTHS OF LOOPED WIRE SUCCESSIVELY AWAY FROM THE SEVERING ZONE IN A RECTILINEAR PATH AND ALONG A COMMON PLANE EXTENDING TRANSVERSELY OF THE WIRE AXES AT THE GRIPPED PORTIONS THEREOF, APPLYING A TERMINAL TO AT LEAST ONE JUXTA-POSITIONED END OF EACH SUCCESSIVE LOOPED WIRE LENGTH WHILE AT REST TO COMPLETE THE CONDUCTORS, AND CONTINUING THE MOVEMENT OF THE COMPLETED CONDUCTORS SUCCESSIVELY ALONG THE SAME PLANE AND IN THE SAME RECTILINEAR PATH AWAY FROM THE TERMINAL ATTACHING ZONE TO A DISCHARGE STATION REMOTE FROM SAID SEVERING ZONE. 